Infiltrated diamond wear resistant bodies and tools

ABSTRACT

Implementations of the present invention include infiltrated diamond tools with increased wear resistance. In particular, one or more implementations of the present invention include a body comprising at least 10% by volume diamond particles that are infiltrated with a binder. Implementations of the present invention also include drilling systems including such infiltrated diamond tool, and methods of forming and using such infiltrated diamond tools.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/368,928, filed Feb. 8, 2012, which claims priority to U.S.Provisional Application No. 61/441,189, filed Feb. 9, 2011. Theseapplications are hereby incorporated herein by reference in theirentirety.

BACKGROUND

Field

The present invention generally relates to tools, such as drilling,mining, and industrial tools. More particularly, the present inventionrelates to wear resistant tools and to methods of making and using suchtools.

Discussion of the Relevant Art

Many drilling, mining, and industrial tools include bodies or padsformed from tungsten carbide (WC) or other wear resistant materials toprovide wear resistance and increased tool life. For example, many typesof earth-boring tools (such as drill bits and reamers) include a bitbody which may be made of steel or fabricated from a hard matrixmaterial such as tungsten carbide (WC). In some cases, a plurality ofcutters (e.g., PCD, TSD, surface sets) is mounted along the exteriorface of the bit body. The cutters are positioned so that, as the bitbody rotates, the cutters engage and drill the formation. Alternatively,the body can comprise the cutter such as with impregnated drill bits.

During drilling the bit bodies of such earth-boring tools can be exposedto high-velocity drilling fluids and formation fluids which carryabrasive particles, such as sand, rock cuttings, and the like. Suchabrasive particles can wear down the bit bodies of the earth boringtools, resulting in lost cutters or even failure of the body.

While steel body bits may have toughness and ductility properties whichmake them resistant to cracking and failure due to impact forcesgenerated during drilling, steel is more susceptible to erosive wear.Tungsten carbide or other hard metal matrix body bits have the advantageof higher wear and erosion resistance as compared to steel bodies.Bodies formed from tungsten carbide or other hard metal matrixmaterials; however, can lack toughness and strength. Thus, bodies formedfrom tungsten carbide or other hard metal matrix materials can berelatively brittle and prone to cracking when subjected to impact andfatigue forces that may be encountered during drilling. This can resultpremature failure of the body. The formation and propagation of cracksin the matrix body may result in the loss of one or more cutters. A lostcutter may abrade against the body, causing further accelerated damage.Furthermore, even tungsten carbide bodies are subject to wear andeventually need to be replaced.

Bodies formed with sintered tungsten carbide may have sufficienttoughness and strength for a particular application, but may lack othermechanical properties, such as erosion resistance. Thus, previousefforts have relied on combinations of materials to achieve a balance ofproperties. Additionally, use of materials having wide particle sizedistributions have been relied upon so as to achieve a close packing ofthe carbide wear particles to increase wear resistance.

Other types of drilling tools, such as reamers, drill stringstabilizers, wear pads, etc. are susceptible to wear during use. It iscommon to set carbide or diamond elements in such tools to increase wearresistance and maintain the gauge of the tool. The setting of carbide ordiamond elements in such tools can be difficult and can otherwiseincrease manufacturing time and costs. Furthermore, locations notcovered by these elements are still subject to relatively rapid wear.

Percussive drilling tools are often formed from high strength steelbodies. The high strength steel bodies provide the percussive drillingtools with the ductility to be subject to high shock and percussiveforces during drilling. Such high strength steel bodies; however, do nothave particularly high wear resistance.

In addition to the foregoing, wear resistant pads or other componentsare frequently added to high wear areas of earthmoving tools andmachines, mining tools, and industrial tools that contact abrasivematerials, such as rock. For instance, hard facing WC is often added toteeth on front-loader buckets and other tools. Commonly, such wear padsare formed from tungsten carbide to provide superior wear resistancecompared to steel. Unfortunately, wear pads can also experience some ofthe problems discussed above. For example, conventional wear pads can berelatively brittle and prone to cracking when subjected to impact andfatigue forces.

Accordingly, there exists a need for a new composition for tools toincrease resistance to wear, while also maintaining other propertiessuch as high strength and toughness.

SUMMARY

Implementations of the present invention overcome one or more of theforegoing or other problems in the art with tools, systems, methodsincluding bodies or substrates formed from infiltrated diamond. Inparticular, one or more implementations of the present invention includea body comprising infiltrated diamond with a binder. The infiltrateddiamond can provide the body with increased wear resistance over steeland tungsten carbide bodies. Additionally, the infiltrated diamond canprovide the body with increased ductility compared to tungsten carbideand other cermet bodies. Furthermore, the infiltration process can allowfor a wide variety of body shapes.

For example, an implementation of tool that is resistant to wearincludes an infiltrated diamond body. The infiltrated diamond bodyincludes a plurality of diamond particles. The diamond particlescomprise at least 25 percent by volume of the infiltrated diamond body.The tool further includes a binder securing the diamond particlestogether.

Another implementation of the present invention includes a method offorming a wear resistant tool. The method involves preparing a matrix bydispersing a plurality of diamond particles throughout a hardparticulate material. The diamond particles comprise at least 25 percentby volume of the matrix. The method further involves shaping the matrixinto a desired shape and infiltrating the matrix with a binder material.

In addition to the foregoing, an implementation of a drilling toolincludes a body having a first end and a second end. The first end ofthe body includes a threaded connector. The tool also includes aninfiltrated diamond body secured to the body. The infiltrated diamondbody comprises diamond and a binder. The diamond comprises at least 10%by volume of the infiltrated diamond body. Additionally, the binder isconfigured to prevent erosion of the infiltrated diamond body duringdrilling.

Additional features and advantages of exemplary implementations of theinvention will be set forth in the description which follows, and inpart will be obvious from the description, or may be learned by thepractice of such exemplary implementations. The features and advantagesof such implementations may be realized and obtained by means of theinstruments and combinations particularly pointed out in the appendedclaims. These and other features will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof which areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1 illustrates a cross-sectional view of an infiltrated diamond bodyaccording to an implementation of the present invention;

FIG. 2 illustrates a reamer including an infiltrated diamond body inaccordance with one or more implementations of the present invention;

FIG. 3 illustrates a cross-sectional view of an infiltrated diamond bodyattached as a substrate to a tool in accordance with one or moreimplementations of the present invention;

FIG. 4 illustrates a polycrystalline diamond (“PCD”) core drill bitincluding an infiltrated diamond body in accordance with one or moreimplementations of the present invention;

FIG. 5 illustrates a PCD rotary drill bit including an infiltrateddiamond body in accordance with one or more implementations of thepresent invention;

FIG. 6 illustrates a drilling system having a drilling tool with aninfiltrated synthetic diamond body according to an implementation of thepresent invention; and

FIG. 7 a chart of acts and steps in a method of forming a tool having aninfiltrated synthetic diamond body in accordance with an implementationof the present invention.

DETAILED DESCRIPTION

Implementations of the present invention are directed towards tools,systems, methods including bodies or substrates formed from infiltrateddiamond. In particular, one or more implementations of the presentinvention include a body comprising infiltrated diamond with a binder.The infiltrated diamond can provide the body with increased wearresistance over steel and tungsten carbide bodies. Additionally, theinfiltrated diamond can provide the body with increased ductilitycompared to tungsten carbide and other cermet bodies. Furthermore, theinfiltration process can allow for a wide variety of body shapes.

In other words, one or more implementations of the present invention canreplace tungsten carbide powders or other cermets used in manufacture ofwear resistant substrates or hardfacing with infiltrated diamond as theprimary wear resistant material. The synthetic diamond can provide thesignificant advantage of having a Mohs hardness of 10, which is a5.times. increase in absolute hardness over the next hardest cermet.Furthermore, one or more implementations use the infiltration of diamondto create almost any shape of body or substrate. Thus, one or moreimplementations of the present invention can replace hard steel bodiesthat are used in shapes that cermets cannot be manufactured into or haveinsufficient ductility for the shock loading. Furthermore, the bindercan be tailored to achieve the required ductility for a particularapplication. In addition to the foregoing, the use of high diamondconcentrations can preclude the need for hand set wear elements.

In particular, one or more implementations include infiltrated diamondbodies. The infiltrated diamond bodies can comprise diamond particles.The diamond particles can include one or more of natural diamonds,synthetic diamonds, polycrystalline diamond products (i.e., TSD or PCD),etc. The diamond particles can comprise anywhere from about 10% to about95% volume of the infiltrated diamond body. In one or moreimplementations, the diamond particles can comprise the primarycomponent of the infiltrated diamond body by volume, and thus, theprimary defense against wear and erosion of the infiltrated diamondbody.

Infiltrated diamond bodies of one or more implementations can form atleast a portion of any number of different tools, particularly toolsthat have need for wear resistance. For example, the infiltrated diamondbodies can be part of tools used to cut or otherwise interface withstone, subterranean mineral formations, ceramics, asphalt, concrete, andother hard materials. These tools may include, for example, drillingtools such as core sampling drill bits, drag-type drill bits, rollercone drill bits, diamond wire, grinding cups, diamond blades, tuckpointers, crack chasers, reamers, stabilizers, drill rods, wear stripsand pads, and the like. For example, the drilling tools may be any typeof earth-boring drill bit (i.e., core sampling drill bit, drag drillbit, roller cone bit, navi-drill, full hole drill, hole saw, holeopener, etc.), and so forth. The Figures and corresponding text includedhereafter illustrate examples of drilling tools including infiltrateddiamond bodies, and methods of forming and using such tools. This hasbeen done for ease of description. One will appreciate in light of thedisclosure herein; however, that the systems, methods, and apparatus ofthe present invention can be used with other tools.

For example, implementations of the present invention can be used toform any type of tool that requires high wear resistance. Such tools caninclude mining, construction, farming, medical (e,g., hip or otherreplacements), and other industrial tools, dies, and gauging.Additionally, the infiltrated diamond bodies can be used in wear andshock applications such as percussive bits, down-the-hole hammers andbits, sonic bits, etc. In one or more implementations, the infiltrateddiamond bodies can replace tungsten carbide hardfacing. Thus, one willappreciate in light of the disclosure herein that the infiltrateddiamond bodies can form part of, or be attached to dozer blades, graderblades, machine undercarriage parts, bucket teeth, grader scrappers,bucket liners, mixer blades, wear plates, tunneling tools, augers, edgesof molding screws, pulverizer mill scrappers, stabilizers, crushinghammers, teeth of dredging bits, cutter teeth, wear parts for farmingtools, feeding screws, extrusion dies, screws, or other tools ormachines.

Referring now to the Figures, FIG. 1 illustrates a cross-sectional viewof an infiltrated diamond body 100 in accordance with one or moreimplementations of the present invention. As shown in FIG. 1, theinfiltrated diamond body 100 can comprise diamond 102 held together by abinder 104. One will appreciate in light of the disclosure herein, thatthe diamond 102 can replace a powered metal or alloy, such as tungstencarbide used in many conventional tools. Alternatively, the infiltrateddiamond body 100 can replace a steel body or component in a conventionaltool. In still further implementations, the infiltrated diamond body 100can replace tungsten carbide hardfacing.

The diamond 102 can comprise one or more of natural diamonds, syntheticdiamonds, polycrystalline diamond products (i.e., TSD or PCD), etc. Thediamond 102 can comprise a wide number sizes, shapes, grain, quality,grit, concentration, etc. as explained in greater detail below. In anyevent, the diamond 102 can comprise at least about 10% volume of theinfiltrated diamond body 100. For example, the diamond 102 can comprisebetween about 25% and about 95% volume of the infiltrated diamond body100. In one or more implementations, the diamond 102 can comprise theprimary component of the infiltrated diamond body 100. In other words,the percent volume of the diamond 102 can be greater than percent volumeany of the other individual components (binder 104, hard particulatematerial etc.) of the infiltrated diamond body 100. Thus, the diamond102 can form the primary defense against wear and erosion of theinfiltrated diamond body 100.

More specifically, in one or more implementations the diamond 102 cancomprise between about 30% and 90% by volume of the infiltrated diamondbody 100. In further implementations, the diamond 102 can comprisebetween about 35% and 75% by volume of the infiltrated diamond body 100.In still further implementations, the diamond 102 can comprise about10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%,80%, 85%, or 90% by volume of the infiltrated diamond body 100.Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein.

In one or more implementations, the diamond 102 can be homogenouslydispersed throughout the infiltrated diamond body 100. In alternativeimplementations, however, the concentration of diamond 102 can varythroughout the infiltrated diamond body 100, as desired. Indeed, asexplained below the concentration of diamond 102 can vary depending uponthe desired characteristics for the infiltrated diamond body 100. Forexample, a large concentration of diamond 102 can be placed in portionsof the infiltrated diamond body 100 particularly susceptible to wear,such as the outer surfaces. The size, density, and shape of the diamond102 can be provided in a variety of combinations depending on desiredcost and performance of the infiltrated diamond body 100. For example,the infiltrated diamond body 100 can comprise sections, strips, spots,rings, or any other formation that contains a different concentration ormixture of diamond than other parts of the infiltrated diamond body 100.For instance, the outer portion of the infiltrated diamond body 100 maycontain a first concentration of diamond 102, and the concentration ofdiamond 102 can gradually decrease or increase towards inner portion ofthe infiltrated diamond body 100.

In one or more implementations the diamond 102 comprises particles, suchas natural diamond crystals or synthetic diamond crystals. The diamond102 can thus be relatively small. In particular, in one or moreimplementation, the diamond 102 has a largest dimension less than about2 millimeters, or more preferably between about 0.01 millimeters andabout 1.0 millimeters. Additionally or alternatively, a volume that isless between about 0.001 mm.sup.3 and about 8 mm.sup.3. In alternativeimplementations, the diamond 102 can have a largest dimension more thanabout 2 millimeters and/or a volume more that about 8 mm.sup.3.

In one or more implementations, the diamond 102 can include a coating ofone or more materials. The coating can include metal, ceramic, polymer,glass, other materials or combinations thereof. For example, the diamond102 can be coated with a metal, such as iron, titanium, nickel, copper,molybdenum, lead, tungsten, aluminum, chromium, or combinations oralloys thereof. In other implementations, diamond 102 may be coated witha ceramic material, such as SiC, SiO, Si02, or the like.

The coating may cover all of the surfaces of the diamond 102, or only aportion thereof. Additionally, the coating can be of any desiredthickness. For example, in one or more implementations, the coating mayhave a thickness of about one to about 20 microns. The coating may beapplied to the diamond 102 through spraying, brushing, electroplating,immersion, vapor deposition, or chemical vapor deposition. The coatingcan help bond the diamond 102 to the binder or hard particulatematerial. Stillfurther, or alternatively, the coating can increase orotherwise modify the wear properties of the diamond 102.

In yet further implementations, the infiltrated diamond body 100 canalso comprise a traditional hard particulate material in addition to thediamond 102. For example, the infiltrated diamond body 100 can comprisea powered material, such as for example, a powered metal or alloy, aswell as ceramic compounds. According to one or more implementations ofthe present invention the hard particulate material can include tungstencarbide. As used herein, the term “tungsten carbide” means any materialcomposition that contains chemical compounds of tungsten and carbon,such as, for example, WC, W2C, and combinations of WC and W2C. Thus,tungsten carbide includes, for example, cast tungsten carbide, sinteredtungsten carbide, and macrocrystalline tungsten. According to additionalor alternative implementations of the present invention, the hardparticulate material can include carbide, tungsten, iron, cobalt, and/ormolybdenum and carbides, borides, alloys thereof, or any other suitablematerial.

One will appreciate in light of the disclosure herein that the amountsof the various components of infiltrated diamond body 100 can varydepending upon the desired properties. In one or more implementations,the hard particulate material can comprise between about 0% and about55% by volume of the infiltrated diamond body 100. More particularly,the hard particulate material can comprise between about 25% and about60% by volume of the infiltrated diamond body 100.

The diamond 102 (and hard particulate material if included) can beinfiltrated with a binder 104 as mentioned previously. In one or moreimplementations the binder material can be a copper-based infiltrant.The binder 104 can function to bind or hold the diamond particles orcrystals together. The binder can be tailored to provide the infiltrateddiamond body 100 with several different characteristics that canincrease the useful life and/or the wear resistance of the infiltrateddiamond body 100. For example, the composition or amount of binder inthe infiltrated diamond body 100 can be controlled to vary the ductilityof the infiltrated diamond body 100. In this way, the infiltrateddiamond body 100 may be custom-engineered to possess optimalcharacteristics for specific materials or uses.

The binder can comprise between about 5% and about 75% by volume of theinfiltrated diamond body 100. More particularly, the binder can comprisebetween about 20% and about 45% by volume of the infiltrated diamondbody 100. For example, a binder 104 of one or more implementations ofthe present invention can include between about 20% and about 45% byweight of copper, between about 0% and about 5% by weight of nickel,between about 0% and about 20% by weight of silver, between about 0% andabout 0.2% by weight of silicon, and between about 0% and about 21% byweight of zinc. Alternatively, the binder 104 can comprise ahigh-strength, high-hardness binder such as those disclosed in U.S.patent application Ser. No. 13/280,977, the entire contents of which arehereby incorporated by reference in their entirety. In one or moreimplementations, such high-strength, high-hardness binders can allow fora smaller percentage by volume of diamond, while still maintainingincreased wear resistance.

One or more implementations of the present invention are configured toprovide tools that are wear resistance. In particular, in one or moreimplementations such tools are configured to also resist wear break-upand erosion. For example, in one or more implementations, the binder isconfigured to prevent erosion of the infiltrated diamond body duringdrilling. One will appreciate in light of the disclosure here that thisis in contrast to impregnated tools that are configured to erode toexpose new diamond during a drilling process.

As mentioned previously, infiltrated diamond bodies 100 according to oneor more implementations of the present invention can form at least partof various different tools. For example, FIG. 2 illustrates a reamingshell 200 that can include one or more infiltrated diamond bodies 100.The reaming shell 200 can also include a first or shank portion 204 witha first end 208 that is configured to connect the reaming shell 200 to acomponent of a drill string. For example, the first end 208 can includea female threaded connector for coupling with another drill stringcomponent. An opposing or second end 206 of the reaming shell 200 canalso be configured to connect the reaming shell 200 to a component of adrill string. As shown by FIG. 2, the second end 206 can include a malethreaded connector.

By way of example and not limitation, the shank portion 204 may beformed from steel, another iron-based alloy, or any other material thatexhibits acceptable physical properties. As shown in FIG. 2, the reamingshell 200 a generally annular shape defined by an inner surface 210 andan outer surface 212. Thus, the reaming shell 200 can define an interiorspace about its central axis for receiving a core sample or allowingfluid to pass there through. Accordingly, pieces of the material beingdrilled can pass through the interior space of the reaming shell 200 andup through an attached drill string. The reaming shell 200 may be anysize, and therefore, may be used to collect core samples of any size.While the reaming shell 200 may have any diameter and may be used toremove and collect core samples with any desired diameter, the diameterof the reaming shell 200 can range in some implementations from about 1inch to about 12 inches.

As shown by FIG. 2, in one or more implementations, the reaming shell200 can include raised pads 202 separated by channels. The raised pads202 can comprise infiltrated diamond bodies 100 as described hereinabove. In one or more implementations the pads 202 can have a spiralconfiguration. In other words, the pads 202 can extend axially along theshank 204 and radially around the shank 204. The spiral configuration ofthe pads 202 can provide increased contact with the borehole, increasedstability, and reduced vibrations. In alternative implementations, thepads 202 can have a linear instead of a spiral configuration. In suchimplementations, the pads 202 can extend axially along the shank 204.Furthermore, in one or more implementations the pads 202 can include atapered leading edge to aid in moving the reaming shell 200 down theborehole.

In at least one implementation, the reaming shell 200 may not includepads 202. For example, the reaming shell 200 can include broaches formedfrom infiltrated diamond bodies 100 instead of pads. The broaches caninclude a plurality of strips. The broaches can reduce the contact ofthe reaming shell 200 on the borehole, thereby decreasing drag.Furthermore, the broaches can provide for increased water flow, andthus, may be particularly suited for softer formations.

In addition to comprising bodies such as pads 202, the infiltrateddiamond bodies 100 can be configured as substrates that line or coatvarious features of a tool. For example, in one or more implementationsthe shank 204 of the reaming shell 200 can comprise an outer substrateor layer formed from an infiltrated diamond body 100. For example, FIG.3 illustrates an infiltrated diamond body 100 a configured as asubstrate. The infiltrated diamond body or substrate 100 a can comprisediamond 102, a binder 104, and optionally a hard particulate material asdescribed above. The infiltrated diamond body or substrate 100 a can beattached to the shank 204 of the reaming shell 200 to increase the wearresistance of the shank 204. For example, the shank 204 can comprisesteel or another suitable material and the infiltrated diamond body orsubstrate 100 a can be brazed or soldered to the shank 204.Alternatively or additionally, the infiltrated diamond body or substrate100 a can be mechanically secured to the shank 204. FIG. 3 illustratesthe infiltrated diamond body or substrate 100 a secured to a reamingshell shank 204. One will appreciate in light of the disclosure hereinthat the infiltrated diamond body or substrate 100 a can be secured toany portion of the tools described herein above to increase the wearresistance thereof.

One will appreciate in light of the disclosure herein that reamingshells 200 are only one type of tool with which infiltrated diamondbodies 100 of the present invention may be used. For example, FIG. 4illustrates a drill bit 400 including one or more infiltrated diamondbodies 100, 100 a. Similar to the reaming shell 200, the drill bit 400can include a shank portion 404 with a first end 408 configured toconnect to a component of a drill string. Also, the drill bit 400 canhave a generally annular shape defined by an inner surface 410 and anouter surface 412. Alternatively, the drill bit 400 may not configuredas a core drill bit, and thus, not have an annular shape.

The crown 402 can comprise an infiltrated diamond body 100 as describedabove. Furthermore, the crown 402 can include a plurality of cutters414. Thus, the infiltrated diamond body forming the crown 402 can beconfigured to hold cutters 414. The cutters 414 can be brazed orsoldered to the crown 402 using a binder, braze, or solder. The cutters414 can comprise one or more of natural diamonds, synthetic diamonds,polycrystalline diamond products (i.e., TSD or PCD), aluminum oxide,silicon carbide, silicon nitride, tungsten carbide, cubic boron nitride,alumina, seeded or unseeded sol-gel alumina, or other suitablematerials. In the illustrated implementation, the cutters 414 comprisePCD. The cutters 414 can be configured to cut or drill the desiredmaterials during the drilling process. Similar to the shank 204 of thereamer 200, in one or more implementations the shank 404 can have aninfiltrated diamond body or substrate 100 a secured thereto to increasethe wear resistance thereof.

The drilling tools shown and described in relation to FIGS. 2 and 4 havebeen coring drilling tools. One will appreciate that the diamondinfiltrated bodies of the present invention can be used to form othernon-coring drilling tools or non-drilling tools as described above. Forexample, FIG. 5 illustrates a drag drill bit 500 including one or moreinfiltrated diamond bodies. In particular, FIG. 5 illustrates aplurality of blades 502 and a bit body 503 formed from infiltrateddiamond bodies. Each of the blades 502 can include one or more PCDcutters 514 or other cutter brazed or soldered to the blades 514. Thedrag drill bit 500 can further include a shank 504 and a first end 508similar to those described herein above. One will appreciate the crown402 and blades 502 shown in FIGS. 4 and 5 can have an increased drillinglife due to the increased wear resistance provided by the diamondinfiltrated bodies used to form them. This can allow a driller toreplace the cutters 414, 514 multiple times before having to replace thedrill bits 400, 500.

As shown by FIG. 5, the infiltrated diamond bodies can allow for thecreation of bit bodies 503 and blades 502 with various features that maybe difficult to create using other more traditional bit bodycompositions. For example, FIG. 5 illustrates that the infiltrateddiamond bit body 503 can include holes 516 for nozzles and blades 502.Similarly, the blades 502 can include recesses for mounting the cutters514 therein.

One will appreciate that the tools (such as 200, 400, 500) formed inwhole or in part from infiltrated diamond bodies 100, 100 a can be usedwith almost any type of machine or system in which wear resistance isneeded or desired. For example, as mentioned above, the infiltrateddiamond bodies 100, 100 a can form in whole or in part any number oftools including, but not limited to, the tools described herein above.For example, FIG. 6, and the corresponding text, illustrate or describeone such drilling system with which tools of the present invention canbe used. One will appreciate, however, the drilling system shown anddescribed in FIG. 6 is only one example of a system with which toolsincluding infiltrated diamond bodies of the present invention can beused.

Specifically, FIG. 6 illustrates a drilling system 600 that includes adrill head 602. The drill head 602 can be coupled to a mast 604 that inturn is coupled to a drill rig 606. The drill head 602 can be configuredto have one or more drill string component 608 coupled thereto. Thedrill string component 608 can include, without limitation, drill rods,casings, reaming shells, and down-the-hole hammers. The drill stringcomponents 608 can in turn be coupled to additional drill stringcomponents 608 to form a drill or tool string 610. One or more of thedrill string components 608 can include one or more infiltrated diamondbodies, For example, one or more of the drill string components 608 caninclude one or more pads 202 formed in whole or in part from aninfiltrated diamond body 100. Alternatively, or additionally, one ormore of the drill string components 608 can include an infiltrateddiamond substrate 100 a secured about an outer surface thereof. In anyevent one will appreciate that the infiltrated diamond bodies 100, 100 acan increase the wear resistance of the drill string components 608.

The drill string 610 can be coupled to a drill bit 612 including one ormore infiltrated diamond bodies 100, 100 a, such as the drill bits 500and 400 described hereinabove. As alluded to previously, the drill bit612 including infiltrated diamond bodies 100, 100 a can be configured tointerface with the material 614, or formation, to be drilled.

In at least one example, the drill head 602 illustrated in FIG. 6 can beconfigured rotate the drill string 610 during a drilling process.Specifically, the drilling system 600 can be configured to apply agenerally longitudinal downward force to the drill string 610 to urgethe drill bit 612 or other tools including infiltrated diamond bodies100, 100 a into the formation 614 during a drilling operation. Forexample, the drilling system 600 can include a chain-drive assembly thatis configured to move a sled assembly relative to the mast 604 to applythe generally longitudinal force to the drill bit 600.

As used herein the term “longitudinal” means along the length of thedrill string 610. Additionally, as used herein the terms “upper,” “top,”and “above” and “lower” and “below” refer to longitudinal positions onthe drill string 610. The terms “upper,” “top,” and “above” refer topositions nearer the mast 604 and “lower” and “below” refer to positionsnearer the drill bit 612.

Thus, one will appreciate in light of the disclosure herein, that thetools of the present invention can be used for various purposes known inthe art. For example, one or more drill string components 608 and adrill bit 600 each including one or more infiltrated diamond bodies 100,100 a can be attached to the end of the drill string 610, which is inturn connected to a drilling machine or rig 606. As the drill string 610and the drill bit 600 are rotated and pushed by the drilling machine606, cutters 414, 514 on the drill bit 600 or the drill bit itself cangrind away the materials in the subterranean formations 614 that arebeing drilled. The wear resistance of the tools including infiltrateddiamond bodies 100, 100 a can last longer and require replacement lessoften.

Implementations of the present invention also include methods of formingtools including infiltrated diamond bodies. The following describes atleast one method of forming tools including infiltrated diamond bodies.Of course, as a preliminary matter, one of ordinary skill in the artwill recognize that the methods explained in detail can be modified. Forexample, FIG. 7 illustrates a flowchart of one exemplary method forproducing a tool including infiltrated diamond bodies using principlesof the present invention. The acts of FIG. 7 are described below withreference to the components and diagrams of FIGS. 1 through 6.

As an initial matter, the term “infiltration” or “infiltrating” as usedherein involves melting a binder material and causing the molten binderto penetrate into and fill the spaces or pores of a matrix. Uponcooling, the binder can solidify, binding the particles of the matrixtogether. The term “sintering” as used herein means the removal of atleast a portion of the pores between the particles (which can beaccompanied by shrinkage) combined with coalescence and bonding betweenadjacent particles.

For example, FIG. 7 shows that a method of forming a wear resistancetool comprise an act 700 of preparing a matrix. Act 700 can includepreparing a matrix of diamond and a hard particulate material. Forexample, act 700 can comprise dispersing a plurality of diamondparticles throughout a hard particulate material. More particularly, act700 can involve preparing a matrix of a powered material, such as forexample tungsten carbide, and dispersing diamond particles 102 therein.In additional implementations, the matrix can comprise one or more ofthe previously described hard particulate materials or diamondmaterials. Additionally, the method can involve dispersing the diamond102 randomly or in an unorganized arrangement throughout the matrix. Act700 can involve dispersing sufficient diamond 102 throughout the matrixsuch that the diamond 102 comprises at least 25 percent by volume of thematrix. In additional implementations, the matrix comprises betweenabout 25% and 95% diamond.

FIG. 7 also shows that the method can comprise an act 710 of shaping thematrix into a desired shape. In one or more implementations of thepresent invention, act 710 can include placing the matrix in a mold. Themold can be formed from a material that is able to withstand the heat towhich the matrix will be subjected to during a heating process. In atleast one implementation, the mold may be formed from carbon. The moldcan be shaped to form a tool having desired features. In at least oneimplementation of the present invention, the mold can correspond to acore drill bit, a reaming pad, or other tool.

FIG. 7 also shows that the method can comprise an act 720 ofinfiltrating the diamond matrix with a binder. Act 720 can involveheating the binder to a molten state and infiltrating the diamond matrixwith the molten binder. For example, in some implementations the bindercan be placed proximate the diamond matrix and the diamond matrix andthe binder can be heated to a temperature sufficient to bring the binderto a molten state. At which point the molten binder can infiltrate thediamond matrix. In one or more implementations, act 720 can includeheating the diamond matrix and the binder to a temperature of at least787.degree.

The binder can comprise copper, zinc, silver, molybdenum, nickel,cobalt, tin, iron, aluminum, silicon, manganese, or mixtures and alloysthereof. The binder can cool thereby bonding to the diamond 102 and thehard particulate material, thereby binding them together. According toone or more implementations of the present invention, the time and/ortemperature of the infiltration process can be increased to allow thebinder to fill-up a greater number and greater amount of the pores ofthe diamond matrix. This can both reduce the shrinkage during sintering,and increase the strength of the resulting tool.

The method can further comprise an act of cooling the infiltrateddiamond matrix to form an infiltrated diamond body 110, 100 a. Themethod can further involve securing the infiltrated diamond body 110,100 a to a tool or a portion thereof. For example, the method caninvolve securing a shank 204 to the infiltrated diamond body 110, 100 a.For example, the method can involve placing a shank 204 in contact withthe diamond matrix. A backing layer of additional matrix, bindermaterial, and/or flux may then be added and placed in contact with thediamond matrix as well as the shank 204 to complete initial preparationof a green tool. Once the green tool has been formed, it can be placedin a furnace to thereby consolidate the tool. Thereafter, the tool canbe finished through machine processes as desired.

Before, after, or in tandem with the infiltration of the diamond matrix,one or more methods of the present invention can include sintering thediamond matrix to a desired density. As sintering involves densificationand removal of porosity within a structure, the structure being sinteredcan shrink during the sintering process. A structure can experiencelinear shrinkage of between 1% and 40% during sintering. As a result, itmay be desirable to consider and account for dimensional shrinkage whendesigning tooling (molds, dies, etc.) or machining features instructures that are less than fully sintered.

Accordingly, the schematics and methods described herein provide anumber of unique products that can be effective for drilling or othertools. Additionally, such products can have an increased wear resistancedue to the relatively large concentration of diamond. The presentinvention can thus be embodied in other specific forms without departingfrom its spirit or essential characteristics. For example, the drillbits of one or more implementations of the present invention can includeone or more enclosed fluid slots, such as the enclosed fluid slotsdescribed in U.S. patent application Ser. No. 11/610,680, filed Dec. 14,2006, entitled “Core Drill Bit with Extended Crown Longitudinaldimension,” now U.S. Pat. No. 7,628,228, the content of which is herebyincorporated herein by reference in its entirety. Still further, theimpregnated drill bits of one or more implementations of the presentinvention can include elongated structures, such as the taperedwaterways described in U.S. patent application Ser. No. 13/217,107,filed Aug. 24, 2011, entitled “Impregnated Drilling Tools IncludingElongated Structures,” the content of which is hereby incorporatedherein by reference in its entirety. The described embodiments are to beconsidered in all respects only as illustrative and not restrictive. Thescope of the invention is, therefore, indicated by the appended claimsrather than by the foregoing description. All changes that come withinthe meaning and range of equivalency of the claims are to be embracedwithin their scope.

1. A solidified infiltrated tool configured to be resistant to wear,wherein the solidified infiltrated tool is selected from the groupconsisting of a drill bit body, a wear pad, and a wear strip, thesolidified infiltrated tool comprising: a matrix having a hardparticulate material and a plurality of diamond particles dispersedthroughout the hard particulate material; and a binder comprising acopper-based infiltrant, wherein the binder secures the hard particulatematerial and the diamond particles together, wherein the diamondparticles comprise the largest component by volume of the solidifiedinfiltrated tool, and wherein the diamond particles are dispersedthroughout the solidified infiltrated tool.
 2. The solidifiedinfiltrated tool as recited in claim 1, wherein the diamond particlescomprise synthetic diamond crystals.
 3. The solidified infiltrated toolas recited in claim 1, wherein the hard particulate material comprisestungsten carbide.
 4. The solidified infiltrated tool as recited in claim1, wherein the diamond particles comprise between about 35 percent andabout 75 percent by volume of the solidified infiltrated tool.
 5. Thesolidified infiltrated tool as recited in claim 1, wherein at least onediamond particle has a largest dimension of between about 0.01millimeters to about 1.0 millimeters.
 6. The solidified infiltrated toolas recited in claim 1, wherein at least one diamond particle has alargest dimension of more than about 2.0 millimeters
 7. The solidifiedinfiltrated tool as recited in claim 6, wherein at least one diamondparticle has a volume of more than about 8 mm³.
 8. The solidifiedinfiltrated tool as recited in claim 1, wherein the binder comprisesbetween about 20 percent and about 45 percent by volume of thesolidified infiltrated tool.
 9. The solidified infiltrated tool asrecited in claim 1, wherein the solidified infiltrated tool is the drillbit body.
 10. The solidified infiltrated tool as recited in claim 9,further comprising a plurality of cutters secured to the solidifiedinfiltrated drill bit body.
 11. The solidified infiltrated tool asrecited in claim 1, wherein the solidified infiltrated tool is the wearpad.
 12. The solidified infiltrated tool as recited in claim 1, whereinthe solidified infiltrated tool is the wear strip.
 13. A wear resistantdrilling tool, comprising: a shank having a first end and a second end,the first end of the shank comprising a threaded connector; and asolidified infiltrated drill bit body secured to the shank, thesolidified infiltrated drill bit body comprising a matrix, the matrixcomprising a hard particulate material, diamond, and a binder, whereinthe binder secures the hard particulate material and the diamondparticles of the matrix together, wherein the diamond comprises thelargest component by volume of the solidified infiltrated drill bitbody, and wherein the diamond is dispersed throughout the solidifiedinfiltrated drill bit body.
 14. The drilling tool as recited in claim13, wherein the diamond comprises synthetic diamonds particles.
 15. Thedrilling tool as recited in claim 13, further comprising a plurality ofcutters secured to the solidified infiltrated drill bit body.
 16. Amethod of forming a wear resistant tool, comprising: preparing a matrixby dispersing a plurality of diamond particles throughout a hardparticulate material; shaping the matrix into a desired shape; andinfiltrating the matrix with a binder material, wherein the bindermaterial comprises a copper-based infiltrant and secures the hardparticulate material and the diamond particles of the matrix together toform an infiltrated tool, wherein the infiltrated tool is selected fromthe group consisting of a drill bit body, a wear pad, and a wear strip,and wherein, following solidifying of the infiltrated tool, the diamondparticles comprise the largest component by volume of the infiltratedtool, and wherein the diamond particles are dispersed throughout theinfiltrated tool.
 17. The method as recited in claim 16, wherein thediamond particles comprise synthetic diamond crystals.
 18. The method asrecited in claim 16, wherein shaping the matrix comprises placing thematrix within a mold.
 19. The method as recited in claim 16, wherein thesolidified infiltrated tool is the drill bit body.
 20. The method asrecited in claim 19, further comprising securing a plurality of cuttersto the solidified infiltrated drill bit body.
 21. The method as recitedin claim 16, wherein the solidified infiltrated tool is the wear pad.22. The method as recited in claim 16, wherein the solidifiedinfiltrated tool is the wear strip.